Medical device control handle with multiple puller wires

ABSTRACT

A medical device control handle or catheter includes deflection assembly and at least one of the following: a disk actuator, a lever actuator and a ring actuator for actuating additional puller wires in manipulation of multiple features of the medical device or catheter independently of each other. The disk actuator has a common rotational axis with but is rotationally independent of the deflection assembly. The lever actuator has a separate rotational axis. The ring is mounted outside of the control handle and rotatable relative to the control handle to actuate another puller wire for manipulating another feature of the catheter. 
     Each of the disk, lever and ring actuators are of a design that allows existing control handles and catheters to be readily modified to include these actuators.

RELATED APPLICATION

This application is a divisional application of U.S. Ser. No. 13/341,840filed on Dec. 30 2011, now issued U.S. Pat. No. 9,162,036, the completedisclosure of which is hereby incorporated herein by reference for allpurposes.

FIELD OF INVENTION

This invention relates to a control handle for medical devices, inparticular, a control handle having mechanisms controlling multiplepuller wires.

BACKGROUND

Electrode catheters have been in common use in medical practice for manyyears. They are used to stimulate and map electrical activity in theheart and to ablate sites of aberrant electrical activity. Atrialfibrillation is a common sustained cardiac arrhythmia and a major causeof stroke. This condition is perpetuated by reentrant waveletspropagating in an abnormal atrial-tissue substrate. Various approacheshave been developed to interrupt wavelets, including surgical orcatheter-mediated atriotomy. Prior to treating the condition, one has tofirst determine the location of the wavelets. Various techniques havebeen proposed for making such a determination, including the use ofcatheters with a mapping assembly that is adapted to measure activitywithin a pulmonary vein, coronary sinus or other tubular structure aboutthe inner circumference of the structure. One such mapping assembly hasa tubular structure comprising a generally circular main regiongenerally transverse and distal to the catheter body and having an outercircumference and a generally straight distal region distal to the mainregion. The tubular structure comprises a non-conductive cover over atleast the main region of the mapping assembly. A support member havingshape-memory is disposed within at least the main region of the mappingassembly. A plurality of electrode pairs, each comprising two ringelectrodes, are carried by the generally circular main region of themapping assembly.

In use, the electrode catheter is inserted into a guiding sheath whichhas been positioned a major vein or artery, e.g., femoral artery, andguided into a chamber of the heart. Within the chamber, the catheter isextended past a distal end of the guiding sheath to expose the mappingassembly. The catheter is maneuvered through movements that includedeflection of a distal portion of the catheter so that the mappingassembly is positioned at the tubular region in the heart chamber. Theability to control the exact position and orientation of the catheterand also the configuration of the mapping assembly is critical andlargely determines how useful the catheter is.

Steerable catheters are generally well-known. For example, U.S. Pat. No.Re 34,502 describes a catheter having a control handle comprising ahousing having a piston chamber at its distal end. A piston is mountedin the piston chamber and is afforded lengthwise movement. The proximalend of the elongated catheter body is attached to the piston. A pullerwire is attached to the housing and extends through the piston, throughthe catheter body, and into a tip section at the distal end of thecatheter body. The distal end of the puller wire is anchored in the tipsection of the catheter. In this arrangement, lengthwise movement of thepiston relative to the housing results in deflection of the catheter tipsection.

The design described in U.S. Pat. No. RE 34,502 is generally limited toa catheter having a single puller wire. If bi-directional deflection isdesire, more than one puller wire becomes necessary. Moreover, if morecontrol is desired, such as contraction of the mapping assembly, anadditional puller wire is needed. Accordingly, a need exists for acontrol handle capable of controlling multiple puller wires withmechanisms which occupy minimal space within a control handle and whichdesign is adaptable to existing control handles.

SUMMARY OF THE INVENTION

The present invention is directed to a medical device control handle orcatheters. As medical devices, especially, electrophysiologicalcatheters, become more complex with more components to actuate, acontrol handle should provide independent control of multiple pullermembers. The control handle of the present invention includes a diskactuator, a lever actuator and a ring actuator for actuating threedifferent puller wires in manipulation of multiple features of themedical device independently of each other.

In one embodiment, the control handle has a housing, a deflectionassembly having a deflection knob and a pulley arm to which deflectionpuller wire(s) are coupled to for deflecting a portion of the medicaldevice in response to rotation of the deflection knob by a user. Thecontrol handle also has a disk actuator that has a common rotationalaxis with the deflection assembly as the disk actuator is mounted on aportion of the pulley arm but is rotationally independent of the pulleyarm. The disk actuator has a tab that extends through an opening formedin the control handle housing so that it is accessible to the useroutside of the housing. The tab is in close proximity to the deflectionknob so that the user can easily control both, even with one hand.

In another embodiment, the control handle has a lever actuator inaddition to the deflection assembly, where the lever actuator has aseparate rotational axis from that of the pulley arm. The lever actuatorcontrols an additional puller wire for manipulating another feature ofthe catheter. In a more detailed embodiment, the lever actuator isdistal of the pulley arm and its rotational axis is oriented generallyperpendicular of the rotational axis of the pulley arm. The controlhandle housing has an opening through which a tab of the lever actuatorextends so that it is accessible to the user outside of the housing.

In yet another embodiment, the control handle has a ring actuator inaddition to the deflection assembly. The ring is mounted outside of thecontrol handle and rotatable relative to the control handle to actuateanother puller wire for manipulating another feature of the catheter.Each of the disk, lever and ring actuators are of a design that allowsexisting control handles and catheters to be readily modified to includethese actuators. The disk actuator can be mounted on existing pulleyarms with minor modifications to existing control handles. The leveractuator and ring actuator can be mounted on existing control handleswith minor modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will bebetter understood by reference to the following detailed descriptionwhen considered in conjunction with the accompanying drawings. It isunderstood that selected structures and features have not been shown incertain drawings so as to provide better viewing of the remainingstructures and features.

FIG. 1 is a side elevational plan view of one embodiment of the catheterof the present invention.

FIG. 1A is an end cross-sectional view of a control handle of FIG. 1,taken along line A--A.

FIG. 1B is a side cross-sectional view of the control handle of FIG. 1,taken along line B--B.

FIG. 1C is a top plan view of the catheter of FIG. 1.

FIG. 2A is a side cross-sectional view of an embodiment of a junction ofa catheter body and an intermediate section, taken along a firstdiameter.

FIG. 2B is a side cross-sectional view of the embodiment of the junctionof FIG. 2A, taken along a second diameter generally perpendicular to thefirst diameter.

FIG. 3 is an end cross-sectional view of the intermediate section ofFIGS. 2A and 2B.

FIG. 4 is a side elevational view of an embodiment of a distal assembly.

FIG. 5 is an end cross-sectional view of a generally straight proximalportion of the distal assembly of FIG. 4, taken along line 5--5.

FIG. 6 is a perspective view of a deflection knob, a first diskactuator, a second disk actuator and a lever actuator of the controlhandle of FIG. 1.

FIG. 7 is a perspective view of an embodiment of a deflection knob ofFIG. 6.

FIG. 8A is an exploded perspective view of an embodiment of the controlhandle of FIG. 1

FIG. 8B is an exploded perspective view of selected components of thecontrol handle of FIG. 8A, including a housing half, pulley arm anddeflection knob.

FIG. 9 is a perspective view of the pulley arm of FIG. 8B

FIG. 10A-10C are schematic diagrams of an embodiment of a control handleof in a neutral configuration, a right deflection configuration, and aleft deflection configuration.

FIG. 11 is a perspective view of an outer surface of an embodiment of afirst control handle housing half.

FIG. 12 is a perspective view of an embodiment of a tension adjustmentdial and locking plate.

FIG. 13 is a perspective view of an outer surface of an embodiment of asecond control handle housing half.

FIG. 14 is a perspective view of an inner surface of an embodiment ofthe second control handle housing half

FIG. 15 is a perspective view of the inner surface of an embodiment ofthe second control handle housing half, with the first and second diskactuators and a lever actuator.

FIG. 16 is a perspective view of the disk actuator of FIG. 15.

FIG. 17 is an exploded perspective view of the lever actuator of FIG.15.

FIG. 18 is a perspective view of an inner surface of an embodiment ofthe first control handle housing half, with an embodiment of a ringactuator.

FIG. 19 is a perspective view of the ring actuator of FIG. 18.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a control handle 16 for use with amedical device with at least two tensile puller members, e.g., pullerwires or the like, for actuating at least two independent movements ormanipulations of components of the medical device. The control handlemay be used with any variety of medical devices, for example, anelectrophysiological (EP) catheter 10 configured for mapping and/orablation of tissue, including the heart, an embodiment of which isillustrated in FIG. 1.

The catheter 10 of FIG. 1 comprises an elongated catheter body 12, adeflectable intermediate section 14 at a distal end of the catheter body12, and a tip section 15 including a distal assembly 17 having, forexample, a helical form, at a distal end of the intermediate section 14.The catheter includes a control handle 16 with multiple puller wireactuators, including actuators for uni- or bi-directional deflection ofthe intermediate section and manipulation of the distal assembly, forexample, to contract the helical form of the distal assembly. Eachactuator can be operated separately and independently without affectingthe other actuator or its puller wire(s).

With reference to FIGS. 2A and 2B, the catheter body 12 comprises asingle, central or axial lumen 18. The catheter body 12 is flexible,i.e., bendable, but substantially non-compressible along its length. Thecatheter body 12 may be of any suitable construction and made of anysuitable material. In one embodiment, the catheter body 12 comprises anouter wall 22 made of a polyurethane or PEBAX. The outer wall 22comprises an imbedded braided mesh of stainless steel or the like toincrease torsional stiffness of the catheter body 12 so that, when thecontrol handle 16 is rotated, the tip section of the catheter 10 willrotate in a corresponding manner.

The outer diameter of the catheter body 12 is not critical, but ispreferably no more than about 8 French. Likewise the thickness of theouter wall 22 is not critical. The inner surface of the outer wall 22 islined with a stiffening tube 20, which can be made of any suitablematerial, preferably polyimide. The stiffening tube 20 is held in placerelative to the outer wall 22 at the proximal end of the catheter body12. A first glue joint 23 is made between the distal ends of thestiffening tube 20 and the outer wall 22 by a fast drying glue, e.g.Super Glue™. Thereafter, a second glue joint 25 is formed between theproximal ends of the stiffening tube 20 and outer wall 22 using a slowerdrying but stronger glue, e.g., polyurethane.

The stiffening tube 20, along with the braided outer wall 22, providesimproved torsional stability while at the same time minimizing the wallthickness of the catheter, thus maximizing the diameter of the singlelumen. The outer diameter of the stiffening tube 20 is about the same asor slightly smaller than the inner diameter of the outer wall 22.Polyimide tubing is suitable because it may be very thin walled whilestill providing very good stiffness. This maximizes the diameter of thecentral lumen 18 without sacrificing strength and stiffness.

Polyimide material is typically not used for stiffening tubes because ofits tendency to kink when bent. However, it has been found that, incombination with an outer wall 22 of polyurethane, PEBAX or othersimilar material, particularly having a stainless steel braided mesh,the tendency for the polyimide stiffening tube 20 to kink when bent isessentially eliminated with respect to the applications for which thecatheter is used. In one embodiment, the outer wall 22 has an outerdiameter of about 0.092 inch and an inner diameter of about 0.063 inchand the polyimide stiffening tube 20 has an outer diameter of about0.0615 inch and an inner diameter of about 0.052 inch.

As shown in FIGS. 2A, 2B and 3, the intermediate section 14 comprises ashorter section of tubing 19 with multiple lumens, for example, first,second and third lumens 30, 31, and 32. In the disclosed embodiment, thetubing 19 also includes fourth, fifth, sixth and seven lumens 33 a, 33b, 33 c and 33 d. The tubing 19 is made of a suitable non-toxic materialwhich is preferably more flexible than the catheter body 12. A suitablematerial for the tubing 19 is braided polyurethane, i.e., polyurethanewith an embedded mesh of braided stainless steel or the like. The outerdiameter of the intermediate section 14, like that of the catheter body12, is preferably no greater than about 8 French. The size of the lumensis not critical. In one embodiment, the intermediate section has anouter diameter of about 7 French (0.092 inch) and the lumens aregenerally about the same size, having a diameter of about 0.022 inch, orselected lumens can have a slightly larger diameter of about 0.036 inch.

A means for attaching the catheter body 12 to the intermediate section14 is illustrated in FIGS. 2A and 2B. The proximal end of theintermediate section 14 comprises an inner counter bore 24 that receivesthe wall 22. The intermediate section 14 and catheter body 12 areattached by glue 29 or the like.

As shown in FIGS. 2A and 2B, extending through the single lumen 18 ofthe catheter body 12 are various components, for example, lead wires andmultiple puller wires, and any other wires or cables. Longitudinalmovement of the puller wires relative to the catheter body 12 enablesuser control of various parts of the catheter via the control handle. Asmentioned, in one embodiment, there are at least first and seconddeflection puller wires 42 for deflecting the intermediate section 14and a third puller wire 35 a for manipulating and adjusting the distalassembly 17 of the tip section 15. The catheter may include additionalpuller wires, for example, fourth, fifth and sixth puller wires 35 b, 35c and 35 d for manipulating and adjusting additional features of thedistal assembly. Each puller wire 42 is made of any suitable metal, suchas stainless steel or Nitinol. Preferably each puller wire has a lowfriction coating, such as a coating of Teflon™ or the like. Each pullerwire has a diameter preferably ranging from about 0.006 inch to about0.012 inch. Preferably both of the puller wires have the same diameter.Flat puller wires may be used in place of round puller wires. Theircross sectional dimensions should be such that they provide comparabletensile strengths as round puller wires.

Alternatively, the puller wires may be replaced in its entirety or inpart by tensile fibers. The fibers may be of a high modulus fibermaterial, preferably having an ultimate tensile strength substantiallyin the range of 412-463 ksi (2480-3200 Mpa) such as High MolecularDensity Polyethylene (e.g., Spectra™ or Dyneema™), a spun para-aramidfiber polymer (e.g., Kevlar™) or a melt spun liquid crystal polymerfiber rope (e.g., Vectran™), or a high strength ceramic fiber (e.g.,Nextel™). The term fiber is used herein interchangeably with the termfibers in that the tensile fiber may be of a woven or braidedconstruction. In any case, these materials tend to be flexible,providing suitable durability when used in wrapped engagement with thepulleys and the like for greater throw in deflecting the catheter tip.Further, they are substantially non-stretching, which increases theresponsiveness to the manipulation of the control handle, andnonmagnetic so that they generally appear transparent to an MRI. The lowdensity of the material causes it to be generally transparent to anx-ray machine. The materials can also be nonconductive to avoidshorting. Vectran™, for example, has high strength, high abrasionresistance, is an electrical insulator, nonmagnetic, is polymeric, andhas low elongation under sustained loading conditions. It is thereforeunderstood that the term “wire” as used herein may be a wire, a tensilefiber, or a tensile member comprising wire segment(s) and tensile fibersegment(s).

A single lumen catheter body 12 may be preferred over a multi-lumen bodybecause the single lumen 18 body can permit better tip control whenrotating the catheter 10. The single lumen 18 permits the componentspassing therethrough to float freely within the catheter body. If suchcomponents were restricted within multiple lumens, they can build upenergy when the handle 16 is rotated, resulting in the catheter body 12having a tendency to rotate back if, for example, the handle isreleased, or if bent around a curve, to flip over, either for which areundesirable performance characteristics.

As also shown in FIG. 3, one deflection puller wire 42 extends throughthe central lumen 18 of the catheter body 12 and into the second lumen31 of the intermediate section 14. Another deflection puller wire 42extends through the central lumen 18 and into the third lumen 32 of theintermediate section 14. In that regard, the lumens 31, 32 should beoff-axis and diametrically opposed to each other for bi-directionaldeflection in a plane. The distal ends of the deflection puller wires 42are anchored to the wall of the tubing 19 near the distal end of theintermediate section 14 by means of T-anchors (not shown) as understoodby one of ordinary skill in the art. In the intermediate section 14,each deflection puller wires 42 extends through a plastic, e.g. Teflon™,sheath 81, which prevents the deflection puller wires 42 from cuttinginto the wall of the tubing 19 of the intermediate section 14 when theintermediate section 14 is deflected.

As shown in FIG. 2B, compression coils 44 in surrounding relation to thedeflection puller wires 42 extend from the proximal end of the catheterbody 12 to the proximal end of the intermediate section 14. Thecompression coils 44 are made of any suitable metal, e.g., stainlesssteel. The compression coils 44 are tightly wound on itself to provideflexibility, i.e., bending, but to resist compression. The innerdiameter of the compression coils 44 is preferably slightly larger thanthe diameter of the puller wires 42. For example, when a puller wire 42has a diameter of about 0.007 inches, the compression coil 44 preferablyhas an inner diameter of about 0.008 inches. The Teflon™ coating on thepuller wire 42 allows them to slide freely within the compression coils44. The outer surface of the compression coils 44 is covered by aflexible, non-conductive sheath 27 to prevent contact between thecompression coils 44 and other components, such as lead wires andcables, etc. In one embodiment, a non-conductive sheath is made ofpolyimide tubing.

The compression coils 44 are anchored at their proximal ends to theproximal end of the stiffening tube 20 in the catheter body 12 by gluejoint 51 (FIG. 2B) and at its distal end near the proximal end of theintermediate section 14 in the second lumen 31 and third lumen 32 byglue joints 49 (FIG. 2B).

With reference to FIG. 4, at the distal end of the intermediate section14 is the distal assembly 17. The distal assembly 17 comprises agenerally straight proximal region 38 and a generally circular mainregion 39. The proximal region 38 is mounted on the intermediate section14 and the main region 39 carries a plurality of electrodes for mappingand/or ablation. In the embodiment of FIG. 5, the distal assembly 17includes a tubing 60. A shape memory member 54 and lead wires 40 forelectrodes carried on the distal assembly extend through the lumen ofthe tubing 60 and into the intermediate section 14 and the catheter body12.

In the disclosed embodiment, the third or contraction puller wire 35 ais provided to contract the generally circular main region 39 to therebychange or reduce its diameter, for example, when mapping or ablatingcircular or tubular regions of the heart. The contraction wire 35 a hasa proximal end anchored in the control handle 16 as described furtherbelow. The contraction wire 35 a extends through the central lumen 18 ofthe catheter body 12, through the fourth lumen 33 a of the intermediatesection 14 (FIG. 3) and into the distal assembly 17 (FIG. 5).

A third compression coil 46 a is situated within the catheter body 12and intermediate section shaft 14 in surrounding relation to thecontraction wire 35 a (FIG. 2A). The third compression coil 46 a extendsfrom the proximal end of the catheter body 12 and to near the distal endof the fourth lumen 33 a of the intermediate section 14. The thirdcompression coil 46 a is made of any suitable metal, such as stainlesssteel, and is tightly wound on itself to provide flexibility, i.e.,bending, but to resist compression. The inner diameter of the thirdcompression coil 46 a is preferably slightly larger than the diameter ofthe contraction wire 35 a. The outer surface of the compression coil 46a is covered by a flexible, non-conductive sheath 68 a, e.g., made ofpolyimide tubing. The third compression coil 46 a preferably is formedof a wire having a square or rectangular cross-sectional area, whichmakes it less compressible than a compression coil formed from a wirehaving a circular cross-sectional area. As a result, the thirdcompression coil 46 a keeps the catheter body 12, and particularly theintermediate section 14, from deflecting when the contraction wire 35 ais manipulated to contract the distal assembly 17 as it absorbs more ofthe compression. The compression coil 46 a is anchored at its proximalend to the stiffening tube 20 of the catheter body 12 by a proximal gluejoint 51 and to the intermediate section 14 by the distal glue joint 49.With reference to the foregoing, it is understood that fourth, fifth andsixth puller wires 35 b, 35 c and 35 d and their respective compressioncoils 46 b, 46 c and 46 d are similarly structured and situated in thecatheter.

Glue joints throughout the catheter 10 may comprise polyurethane glue orthe like. The glue may be applied by means of a syringe or the likethrough a hole made in the tubing walls. Such a hole may be formed, forexample, by a needle or the like that punctures the tubing walls wherethe needle is heated sufficiently to form a permanent hole. The glue isthen introduced through the hole to wick around the component(s) withinthe tubing to form a glue joint about the entire circumference of thecomponent(s).

The lead wires 40 attached to the ring electrodes on the distal assembly17 extend through the first lumen 30 of the intermediate section 14(FIG. 2A), through the central lumen 18 of the catheter body 12, throughthe control handle 16, and terminate at their proximal end in aconnector (not shown) which is connected to an appropriate monitor orother device for receiving and displaying the information received fromthe ring electrodes. The portion of the lead wires 40 extending throughthe central lumen 18 of the catheter body 12, control handle 16 andproximal end of the intermediate section 14 is enclosed within aprotective sheath 63, which can be made of any suitable material,preferably polyimide.

An electromagnetic position sensor (not shown) is mounted in or near thedistal assembly 17, e.g., in the distal end of the intermediate section14. A sensor cable 36 extends from the sensor into the lumen 30 (FIG.2A) of the intermediate section (along with the electrode lead wires40), into the central lumen 18 of the catheter body 12 and into thecontrol handle 16 where it terminates in a suitable connector (notshown).

As illustrated in FIG. 1, the control handle 16 comprises a generallyelongated handle housing, which can be made of any suitable rigidmaterial. The elongated housing defines a longitudinal axis 64 and canbe of a unitary construction or of two opposing halves 16 a, 16 b thatare joined by glue, sonic welding or other suitable means along a seam37. The housing can be divided into a distal portion 16D, a mid-portion16M and a proximal portion 16P.

In accordance with the present invention, the control handle 16 providesmultiple puller wire actuators. With reference to FIG. 6, the controlhandle 16 has at the mid-portion 16M a deflection control assembly 13for bi-directional deflection of the intermediate section 14 by means ofthe pair of puller wires 42. The mid-portion of the control handle alsoprovides a third puller wire actuator 26 and a fourth puller wireactuator 27.

With reference to FIGS. 1A and 1B, the deflection control assembly 13includes a rotatable deflection knob 50 mounted outside of the handlehousing 16 a and a pulley arm 52 inside the control handle 16 in themid-portion of the control handle. The knob 50 (FIG. 7) has a generallyflat body 56 with a generally oval cross-sectional shape. A peripherallip 57 surrounds the body 56. Mounted on the control handle 16, the body56 lies in a plane that is generally parallel with the longitudinal axis64 of the control handle as best seen in FIG. 1C. The body 56 remainswithin the plane during rotation of the knob.

With reference to FIGS. 1A and 9, the pulley arm 52 has a main body witha generally rectangular cross-section and a center bore 53 extendingthrough the main body that divides the body into two halves. In eachhalf is a through-opening 59 that is occupied by a respective pulley 55(FIG. 1A) adapted to rotate about its own axis. At each end of thecenter bore 53 is a radial bearing formation 61 a and 61 b with acircular cross-section. A respective formation is received in athrough-hole 62 a and 62 b formed in the respective control handlehousing halves 16 a and 16 b for supporting the pulley arm 52 within thecontrol handle. The radial bearing formation 61 a adjacent the knob hasa greater axial dimension D (FIG. 9) than the opposing radial bearingformation 61 b for direct rotational coupling with the knob 50 such thatthe knob 50 and the pulley arm 52 have a common rotational axis 69 thatis generally perpendicular to the longitudinal axis 64 of the controlhandle. In the disclosed embodiment, an interlocking formation ofalternating ridges 65 and recesses 66 are provided on interfacing matingsurfaces of the knob 50 and the radial bearing formation 61 a. Moreover,the ridges 65 (FIG. 7) on an inner mating surface 68 of the knob 50 areelongated to prevent slippage between the knob 50 and the radial bearingformation 61 a when the knob is rotated by the user. Moreover, raisedguides 67 (FIGS. 1B and 11) are provided on an outer surface of housinghandle 16 a to block elongated ridges 65 so as to limit the range ofrotation of the knob 50 and prevent over-rotation and breakage ofdeflection puller wires 42. Glue, e.g, epoxy can be applied between themating surface to adhere the knob 50 and the pulley arm 52, or they canbe fastened together with screws or the like. Accordingly, rotation ofthe knob 50 by the user rotates the pulley arm to actuate the deflectionpuller wires 42, as illustrated in FIGS. 10A-10C. The pair ofbi-directional deflection puller wires 42 enter the control handle 16via a port 74 in the distal end of the control handle. The puller wiresenter the pulley arm 52 through a slit opening 76 (FIG. 9) and each wireis wrapped or wound about a respective pulley 55 (FIG. 1A) about 180degrees before exiting the pulley arm through the slit opening. Aproximal end of each puller member 42 is anchored in a stop 72 that isadjustably but fixedly mounted toothed slots 78 (FIG. 8) in the controlhandle 16. By rotating the knob 50 in one direction, the pulley arm 52is rotated in that direction drawing on the puller wire 42 on that sideto deflect the intermediate section 14 in that direction. A similarpulley arm is described in U.S. Pat. No. 7,377,906, the entiredisclosure of which is hereby incorporated by reference.

Because of the repeated cycles of bending each deflection puller wire 42can experience around its pulley 55, the segment of each puller wirewithin the control handle, and especially around the pulleys, maycomprise a tensile fiber segment such as described hereinabove, whichcan better withstand stress and strain. To that end, a crimped connector73 (FIGS. 10A-10C) is provided to connect a proximal end of each firstand second distal puller wire segments 42D to a distal end of arespective proximal tensile fiber segment 42P.

With reference to FIGS. 1A and 1B, mounted on the radial bearingformation 61 b of control handle housing half 16 b and opposing thedeflection knob 50 is a tension adjustment assembly 43 which includes atension adjustment dial 80 that is coupled to and indirectly engagedwith the pulley arm 52 by various mechanisms and parts. The dial 80allows a user to adjust the ease with which the deflection knob 50 canbe rotated. In the illustrated embodiment, the tension adjustmentassembly 43 includes the dial 80 (FIG. 12), a locking plate 82 (FIG.12), a tension cap screw 83, a retaining nut 84 and a washer 85. The nut84 has an end 87 (FIG. 14) with a polygonal (e.g., hexagonal) shape thatlocks with the through-opening 62 b to prevent rotation of the nut 84when the tension cap screw 83 is rotated to adjust the compression loadapplied to assembly 43 against the washer 85. The dial 80 has two prongs86 (FIG. 12) that extend through the locking plate 82 and into guidinggrooves 88 (FIG. 13) formed on an outer surface of the housing half 16 bwhich limits the range of rotation of the dial 80. A user rotates thedial 80 to adjust the tightness or tension of the rotational movement ofdeflection arm 50 by effectively compressing or releasing the pulley arm52 against the washer 85 (e.g., a Belleville type) and the controlhandle housing half 16 b. A suitable deflection assembly is described inU.S. Pat. No. 7,377,906, the entire disclosure of which is herebyincorporated by reference.

In accordance with a feature of the present invention, the controlhandle includes the second actuator 26 for controlling an additionalpuller wire (or contraction wire) 35 a. With reference to FIGS. 1A, 1Band 15, the second actuator 26 is mounted on the radial bearingformation 61 a between the main body of the pulley arm 52 and thecontrol handle housing half 16 a, adjacent the deflection knob 50. Thesecond actuator 26 has a disk-shaped body 90 a with a centerthrough-hole 92 through which the radial bearing formation 61 a isinserted. The second actuator has an elongated tab 94 b extending from aperiphery of the disk-shaped body which extends through a through-slot96 a in the housing half 16 a. An enlarged handle 98 is mounted on anend of the tab 94 b to facilitate manipulation by the user. The actuator26 is thus rotatable about the radial bearing formation 61 a (and henceabout the rotational axis 69) within a range as limited by a length ofthe through-slot 96 a.

The puller wire 35 a for controlling an additional feature also entersthe control handle through the port 74. A raised center divider 100 isformed in the housing handle 16 b to guide the puller wire toward theactuator 26. The puller wire wrapped around the radial bearing formation61 a and anchored to the body 90 a. In the disclosed embodiment, athrough-hole 102 is formed on the body 90 a for receiving a proximal endof the puller wire 35 a which is tied in a knot to anchor the proximalend to the body. A second through-hole 103 may be provided as analternate anchor position for the puller wire 35 a.

With reference to FIGS. 1A, 1B and 15, the third actuator 27 forcontrolling yet another additional puller wire 35 b is mounted on theopposing radial bearing formation 61 b between the main body of thepulley arm 52 and the control handle housing half 16 b, adjacent thetension adjustment dial 80. The third actuator 27 and its puller wire 35b are similar in structure and function to the second actuator 26 andits puller wire 35 a.

Thus, with either actuator 26 or 27, as the actuator is rotated aboutthe rotational axis 69 in one direction, the respective puller wire iswrapped around the respective radial bearing formation and drawnproximally from its original position to actuate the respective feature.When the actuator is rotated in the opposite direction, the puller wireand the feature are released to assume their original positions.

It is further understood that additional disk actuators can be mountedon either of the radial bearing formation. Because each actuator isrotationally independent of the radial bearing formation on which it ismounted each actuator can be operated independently of the pulley armand each other by the user to control a feature without affecting anyother feature.

In accordance with a feature of the present invention, an additionallever actuator 28 is provided in the distal portion of the controlhandle. The actuator 28 is rotatable about an axis that is at leastparallel, if not coaxial, with the longitudinal axis 64 of the controlhandle. In the illustrated embodiment of FIG. 17, the actuator has anelongated body 110 with an outer end 112 adapted for manipulation by theuser for rotation at an inner end 114 about a longitudinal dowel pin 115mounted in the control handle housing half 16 b. The inner end 114 has afemale snap-fit formation that rotatably engages the dowel pin 115. Theouter end extends through a transverse through-slot 116 (FIG. 11) formedin the housing half 16 a so that the outer end 112 is accessible to theuser, with the range of rotation being limited by the length of the slot116. The actuator 28 has a shroud portion 118 that extends transverselyto the elongated body so that the actuator resembles a “t”. The shroudportion 118 is outside of the control handle 16 and has a profile (e.g.curved) matching the profile of the housing half 16 a to effectivelyseal the slot 116 and protect the interior of the control handle fromexposure.

A puller wire 35 c for controlling yet another additional feature alsoenters the control handle through the port. The puller wire is guided bythe raised divider 100 and extends below the dowel pin 115 and around alongitudinal dowel pin 120 mounted off-set from the longitudinal axis ofthe dowel pin 115 in the control handle housing half 16 a. A proximalend of the puller wire 35 c is anchored to a junction 122 of theelongated body 110 and the shroud portion 118. Thus, when the userrotates the actuator 28 away from the dowel pin 120, the puller wire 35c is drawn proximally from its original position to actuate the feature.When the actuator is rotated toward the dowel pin, the puller wire andthe feature are released to assume their original positions.

In accordance with a feature of the present invention, the controlhandle 16 includes a fourth or ring actuator 130 for controlling anotheradditional puller wire 35 d. In the illustrated embodiment of FIGS. 11and 18, the fourth actuator 130 is mounted on the proximal portion 16Pof the control handle and has a rotational axis coaxial withlongitudinal axis 64 of the control handle. In the illustratedembodiment, the actuator 130 has a generally cylindrical body or ring131 (e.g., a frusto-conical configuration) that is mounted outside ofthe control handle in a circumferential relationship therewith. Acircular band of outer surface of the housing halves 16 a and 16 b underthe ring 131 is depressed relative to the surrounding outer surface toform a nest 132 so that the ring is nested in its longitudinal positionalong the control handle while being allowed circumferential rotationrelative to the control handle. The body has a slit 133 extending in adirection along the longitudinal axis so that the body can be mounted onthe control handle by slipping it over the proximal end of the controlhandle. An aperture 134 is formed in the body diametrically opposite ofthe slit.

The puller wire 35 d for controlling a further additional feature entersthe control handle through the port 74. The puller wire 35 d extendsalong in a longitudinal groove (not shown) formed in the inner surfaceof the housing half 16 a from the port 74 and around the opening 62 a tobypass the pulley arm 52. The puller wire 35 d is then guided in thedistal portion 16D of the control handle 16 by a proximal transversedowel pin 135 and a distal transverse dowel pin 136 mounted in thehousing half 16 a and passes through the aperture 134 in the housinghalf 16 a to reach the fourth actuator 130 where a proximal end of thepuller wire is anchored to the ring actuator 130. A proximal portion ofthe puller wire 35 d is received in a groove with a predeterminedpattern (e.g., spiral) which is filled with glue or the like to anchorthe proximal end to the ring actuator.

As a user rotates the actuator 130 in one direction, the puller wire 35d is drawn proximally through the aperture 134 to wrap around the nest132 between the control handle 16 and the ring 131 to actuate a feature.When the actuator 130 is rotated in the opposite direction, the pullerwire 35 d and the feature are released to return to their originalpositions. An O-ring (not shown) may be provided in the nest 132 betweenthe control handle 16 and the ring 131 to provide friction so as torender the actuator 130 self-holding.

In use, a suitable guiding sheath is inserted into the patient with itsdistal end positioned at a desired location. An example of a suitableguiding sheath for use in connection with the present invention is thePreface™ Braiding Guiding Sheath, commercially available from BiosenseWebster, Inc. (Diamond Bar, Calif.). The distal end of the sheath isguided into one of the chamber, for example, the atria. A catheter inaccordance with an embodiment of the present invention is fed throughthe guiding sheath until its distal end extends out of the distal end ofthe guiding sheath. As the catheter is fed through the guiding sheath,the distal assembly 17 is straightened to fit through the sheath. Oncethe distal end of the catheter is positioned at the desired location,the guiding sheath is pulled proximally, allowing the deflectableintermediate section 14 and distal assembly 17 to extend outside thesheath, and the distal assembly 17 returns to its original shape due toits shape-memory.

The user may then manipulate the deflection 50 to deflect intermediatesection 14 Turning the deflection knob 50 in one direction deflects theintermediate section 14 to that direction. Turning the deflection 50 inthe opposite direction deflects the intermediate section 14 to thatopposite direction. The user may then adjust the generally circular mainregion 39 of the distal assembly 17 by rotating the first actuator 26 inone direction or another to fit a pulmonary vein or other tubularstructure. In the disclosed embodiment, by rotating the dial in onedirection, the contraction wire 35 is drawn proximally to tighten anddecrease the diameter of the generally circular region 39 and byrotating the dial in the other direction, the third puller orcontraction wire 35 a is loosened to release the generally circularregion 39 to its original diameter. Preferably at least about 50%, morepreferably at least about 70%, and still more preferably at least about80% of the circumference of the generally circular main region is incontact with a circumference inside the tubular region. The circulararrangement of the electrodes on the generally circular portion 39permits measurement of the electrical activity at that circumference ofthe tubular structure so that ectopic beats between the electrodes canbe identified. The size of the generally circular main region 39 permitsmeasurement of electrical activity along a diameter of a pulmonary veinor other tubular structure of or near the heart because the circularmain region has a diameter generally corresponding to that of apulmonary vein or other tubular structure. Because the first actuator 26and the deflection knob 50 are not rotationally coupled, each can becontrolled independently of the other.

In accordance with a feature of the present invention, the first andsecond actuators are advantageously of designs that allow them to beadded to existing control handles incorporating the pulley arm 52without significant modifications to the structure of the control handleor interference with its function and operation. Likewise, the third andfourth actuators can be readily incorporated in existing controlhandles.

The preceding description has been presented with reference to presentlypreferred embodiments of the invention. Workers skilled in the art andtechnology to which this invention pertains will appreciate thatalterations and changes in the described structure may be practicedwithout meaningfully departing from the principal, spirit and scope ofthis invention. For example, the catheter can be adapted such that thethird puller wire advances and retracts another component such as aguide wire or a needle. As understood by one of ordinary skill in theart, the drawings are not necessarily to scale. Accordingly, theforegoing description should not be read as pertaining only to theprecise structures described and illustrated in the accompanyingdrawings, but rather should be read consistent with and as support tothe following claims which are to have their fullest and fair scope.

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 10. Anelectrophysiological catheter having at least a first feature subject tomanipulation by a user, the catheter comprising: an elongated catheterbody, the first feature being distal of the catheter body; a controlhandle; and a plurality of puller wires extending from the controlhandle and through at least the elongated catheter body, wherein thecontrol handle comprises: a housing; a deflection assembly comprising: adeflection actuator adapted for rotation by the user; a pulley armadapted for rotation about a rotational axis in response to rotation ofthe deflection actuator, at least a first of the puller wires coupled tothe pulley arm, wherein rotation of the pulley arm actuates the at leastfirst puller wire; a disk actuator adapted for rotation about therotational axis by the user; and a second of the puller wires coupled tothe disk actuator, wherein rotation of the disk actuator actuates thesecond puller wire to manipulate the first feature, wherein the pulleyarm has a radial bearing formation defining the rotational axis, and thedisk actuator is positioned on the radial bearing formation and adaptedto wrap the second puller wire on the radial bearing formation when thedisk actuator is rotated by the user, the disk actuator and the pulleyarm being rotationally independent of each other.
 11. A catheter ofclaim 10, the housing has an opening and the disk actuator has a tabextending through the opening to outside of the housing.
 12. A catheterof claim 10, the pulley arm has a main body and the disk actuator ispositioned between the main body and the housing of the control handle.13. An electrophysiological catheter having at least a first featuresubject to manipulation by a user, the catheter comprising: an elongatedcatheter body, the first feature being distal of the catheter body; acontrol handle defining a longitudinal axis; and a plurality of pullerwires extending from the control handle and through at least theelongated catheter body, wherein the control handle comprises: ahousing; a deflection assembly comprising: a deflection actuator adaptedfor rotation by the user; a pulley arm adapted for rotation about afirst rotational axis in response to rotation of the deflectionactuator, at least a first of the puller wires coupled to the pulleyarm, wherein rotation of the pulley arm actuates the at least firstpuller wire; and a lever actuator adapted for rotation about a secondrotational axis by the user , the second rotational axis being generallyparallel with the longitudinal axis of the control handle, a second ofthe puller wires being coupled to the lever actuator and rotation of thelever actuator actuates the second puller wire to manipulate the firstfeature, and wherein the lever actuator and the pulley arm arerotationally independent of each other.
 14. An electrophysiologicalcatheter of claim 13, wherein the housing has an opening and the levelactuator has an end extending through the opening to outside thehousing.
 15. An electrophysiological catheter of claim 13, wherein thelevel actuator has a shroud portion adapted to cover the opening.
 16. Anelectrophysiological catheter having at least a first feature subject tomanipulation by a user, the catheter comprising: an elongated catheterbody, the first feature being distal of the catheter body; a controlhandle defining a longitudinal axis; and a plurality of puller wiresextending from the control handle and through at least the elongatedcatheter body, wherein the control handle comprises: a housing; adeflection assembly comprising: a deflection actuator adapted forrotation by the user; a pulley arm adapted for rotation about a firstrotational axis in response to rotation of the deflection actuator, atleast a first of the puller wires coupled to the pulley arm, whereinrotation of the pulley arm actuates the at least first puller wire; anda ring actuator mounted on the control handle and adapted for rotationabout the longitudinal axis of the control handle, a second of thepuller wires being coupled to the ring actuator and rotation of the ringactuator actuates the second puller wire to manipulate the firstfeature, wherein the ring actuator and the pulley arm are rotationallyindependent of each other.
 17. An electrophysiological catheter of claim16, wherein rotation of the ring actuator wraps the second puller wirearound the control handle.
 18. An electrophysiological catheter of claim16, wherein the housing has an opening and a proximal portion of thesecond puller wire extends through the opening and is anchored to thering actuator.